Elastomer compositions with silane functionalized silica as reinforcing fillers

Abstract

Certain embodiments described herein are directed to silane functionalized fillers that may be, for example, covalently coupled to a polymer. In some examples, devices that include the filler reinforced polymer compositions are also described.

What is claimed is: 
     
       1. A composition suitable for use in high temperature downhole environments greater than 150° C. comprising a fluoropolymer covalently coupled to a filler through a thermally stable silane coupling agent, the fluoropolymer comprising a cure site monomer incorporated therein, wherein the silane coupling agent is bonded to the cure site monomer of the fluropolymer and wherein the silane coupling agent has a chemically identical reactive moiety to the cure site monomer and wherein the filler is surface treated with the silane coupling agent; and the cure site monomer is selected from one of bromine-containing olefins, bromine-containing vinyl ethers, iodine-containing olefins, iodine-containing vinyl ethers, fluorine-containing olefins having a nitrile group, fluorine-containing vinyl ethers having a nitrile group, and non-conjugated dienes. 
     
     
       2. The composition of  claim 1 , in which the fluoropolymer is synthesized using monomers selected from the group consisting of vinylidene fluoride (VDF), tetrafluoroethylene (TFE), hexafluoropropylene (HFP), chlorotrifluoroethylene (CTFE), and a perfluoro(alkylvinyl ether) (PAVE). 
     
     
       3. The composition of  claim 2 , in which the filler is selected from the group consisting of precipitated silica, amorphous silica, vitreous silica, fumed silica, fused silica, quartz, glass, aluminum, aluminum-silicate, copper, tin, talc, inorganic oxides, steel, iron, asbestos, nickel, zinc, silver, lead, marble, chalk, gypsum, barites, graphite, carbon black, and treated carbon black. 
     
     
       4. The composition of  claim 1 , wherein the silane coupling agent has the formula Q m -Si—Z n , where Q comprises one or more groups that can provide covalent attachment to the polymer, Z comprises one or more groups that can provide covalent attachment to the filler, and the sum of m+n is equal to four. 
     
     
       5. The composition of  claim 4 , wherein Q is —R″-G or —CR′ 2 —CR′—R″-G, where R′ is a hydrogen or a fluorine, R″ is a linear or branched C 1 -C 18  alkyl group, optionally containing one or more ether oxygen atoms and optionally fluorinated, and G is a halogen, a nitrile group, or a vinyl group. 
     
     
       6. The composition of  claim 1 , in which all of the reactive sites of the filler are covalently coupled to the silane coupling agent. 
     
     
       7. The composition of  claim 1 , wherein the silane coupling agent has chemically identical reactive moiety as the pendant group of the cure site monomer. 
     
     
       8. A moving or progressive cavity motor or pump assembly having an inlet end and an outlet end for use in a downhole environment, the motor or pump comprising:
 a housing; 
 a rotor and a stator disposed within the housing, wherein a surface of the rotor or the stator is made of an elastomer material to permit a seal to form between contacting surfaces of the rotor and the stator; wherein the elastomer material comprises a fluoropolymer covalently coupled to a filler through a thermally stable silane coupling agent, wherein the silane coupling agent is bonded to a cure site moiety of the fluropolymer and wherein the silane coupling agent has a chemically identical reactive moiety to a cure site moiety of the fluoropolymer and wherein the filler is surface treated with the silane coupling agent. 
 
     
     
       9. The motor or pump of  claim 8 , in which the polymer is a fluoropolymer synthesized using monomers selected from the group consisting of vinylidene fluoride (VDF), tetrafluoroethylene (TFE), hexafluoropropylene (HFP), chlorotrifluoroethylene (CTFE), and a perfluoro(alkylvinyl ether) (PAVE). 
     
     
       10. The motor or pump of  claim 9 , in which the filler is selected from the group consisting of precipitated silica, amorphous silica, vitreous silica, fumed silica, fused silica, quartz, glass, aluminum, aluminum-silicate, copper, tin, talc, inorganic oxides, steel, iron, asbestos, nickel, zinc, silver, lead, marble, chalk, gypsum, barites, graphite, carbon black, and treated carbon black. 
     
     
       11. The motor or pump of  claim 8 , wherein the silane coupling agent has the formula Q m -Si—Z n , where Q comprises one or more groups that can provide covalent attachment to the polymer, Z comprises one or more groups that can provide covalent attachment to the filler, and the sum of m+n is equal to four. 
     
     
       12. The motor or pump of  claim 11 , wherein Q is —R″-G or —CR′ 2 —CR′—R″-G, where R′ is a hydrogen or a fluorine, R″ is a linear or branched C 1 -C 18  alkyl group, optionally containing one or more ether oxygen atoms and optionally fluorinated, and G is a halogen, a nitrile group, or a vinyl group. 
     
     
       13. The motor or pump of  claim 8 , wherein the fluoropolymer comprises a cure site monomer incorporated therein. 
     
     
       14. The motor or pump of  claim 13 , wherein the silane coupling agent has chemically identical reactive moiety as the pendant group of the cure site monomer. 
     
     
       15. The motor or pump of  claim 13 , wherein the cure site monomer is selected from one of bromine-containing olefins, bromine-containing vinyl ethers, iodine-containing olefins, iodine-containing vinyl ethers, fluorine-containing olefins having a nitrile group, fluorine-containing vinyl ethers having a nitrile group, and non-conjugated dienes.